Reboring jig



March 31, 1953 E. L; SCHLAGE 2,633,040

REBORING JIG Filed Jan. 7. 1252 2 SHEETS-SHEET 1 FIG.

IN V EN TOR. v EPNEiT L. 55/121765 March 31, 1953 SCHLAGE 2,633,04Q

REBORING JIG Filed Jan. 7, 1952 2 SHEETS-SHEET 2 L Li FIG- 6 IN V EN TOR. [PNBT Luff/1146! Arraeusr Patented Mar. 31, 1953 REBORING J IG Ernest L. Schlage, Burlingame, Calif., assignor to Schlage Lock Company, a corporation Application January 7, 1952, Serial N 0. 265,241

. 12 Claims.

. 1 My invention relates to tools especially designed for the installation of tubular or cylindrical locks in doors. In many lock installations, the door panel is initially bored from its edge with a horizontal circular cylindrical hole and is also bored through from one side face of the door to the 1 other (or from both faces toward the center) with an intersecting or through hole having a horizontal axis in the same plane as the edge-bored hole. The distance from the edge of the-door to the axis of the through hole is referred to as the .backset distance and that dimension varies with different locks. It happens frequently that a lock initially installed in a door is fo'r'some reason -later on to be replaced with a lock having a some- .what different backset. The installation of the .different lock cannot be accomplished easily or at all with the usual boring tools, since the pilot ;or lead thread on the usual boring bit has no material into which to engage. Furthermore, it is difiicult to cut a true and straight circular cylindrical hole in avdoor panel if a somewhat displaced hole already exists in the panel. It is therefore an object of my invention to pro- .vide a reboring jig effective for use in providing a-second slightly offset hole through a door panel having its axis displaced from the axis of a hole -previously existing through the panel.

Another object of my invention is to provide a .reboring jig whichcan be used to enlarge a hole of the same backset.

Another object of my invention is toprovide a vreboring tool which can be utilized in connection with other special tools for use in look mounting,

A still further object of my invention is to pro- ..vide a reboring tool effective to leave a substan- -tially circular cylindrical hole through the door lscribed inthe accompanying description and il-.

lustrated in the accompanying drawings in which i Figure l is for the most part a cross section on a general horizontal plane through a door panel and through a reboring jig of my invention mounted thereon, some portions being shown in plan and parts of the door pane1 being broken away to reduce the size of the figure.

Figure 2 is a view to an enlarged scale showing.

in plan the mechanism for orienting the edge bore guide.

Figure 3 is a cross section the plane of which is indicated by the line 3-3 of'Figure 1.

Figure 4 is a cross section, the plane of which is indicated by the line 4-4 of Figure 2.

Figure 5 is a cross section, the plane of which is indicated by the line 5-5 of Figure 4.

Figure 6 is a view in cross section quite similar to. Figure 1 but showing the reboring tool in use on the opposite side of the door panel.

Figure 7 is a plan to an enlarged scale of a -modified form of edge bore guide mechanism location.

Figure 10 is a view comparable to Figures 8 and '9 but showing the parts in a still difierent relavtive location. i V

While the reboring jigof my invention can be incorporated in a number of diiferent ways depending in part on the particular environment .in which it is to be utilized and dependin also upon other engineering'factors, it has been successfully incorporated substantially as shown herein for use inconnection with a door panel 6 of wood or comparable material. The panel is defined .by a side face 1, another side face 8, 'and an end or edge face 9. The panel 6 has previously been provided with an edge bore or hole j I I circular cylindrica1 in contour and symmetrical about alongitudinal axis l2 disposed ina horizontal plane. The axis I2 is also perpendicular to the edge 9 of the bore providing that edge is not beveled. In some instances a bevel is provided but in all cases the axis 12 is substantially parallel to the vertical planes defining .the door side faces I and 8. Also, due to a previous lock. installation, the door panel 6 is pro- .vided with a cross bore or hole l3 circular cylindrical in contour, and usually is considerably larger than the bore H. The hole I3 is symmetrical about an axis [4 in the same horizontal plane as the axis l2 and at right angles thereto, being also perpendicular to the planes of the faces land 8. In accordance with my invention. there is provided a mechanism for utiliz- 3 ing the edge bore II as a partial guide and for providing an additional, displaced cross bore from one side of the door to the other.

Since the thickness of different door panels varies and even changes from time to time, though the nominal thickness may be the same, I provide a structure which includes an upper clamp plate It and a lower clamp plate I! (shown in phantom in Figure 3) the two clampplates being designed firmly to grip the opposite faces I and 8 of the door. The clamp plates are connected by pivot pins I8 and I9 to a lever 2| carryin a circular cylindrical sleeve 22 designed to have its axis 23 coincide with the axis |2 ofgtheedge bore. A suitable thumb wheel 25 operates a clamping pad 24 against an extension 26 of the lower clamp member IT, to' grip'the door. A structure of this general type also provided with a marking device 21 is disclosed in my CODBIldaingapplication, Serial No. 185,018, filed September 15; 1950 and entitl d Boring Jig. Muchof the boring jig structure is not consequential in connection with the present mechanism yet part of itis'utilized with the present structure,

I provide an arrangement for operating with the clamping device to serve as a mounting and guiding member. "The tube 22 is made to serve asa support for a centering plug 4| introduced therein. The plug 4| is provided with a locating'portion 42 having a close sliding fit within the barrel 22. It is also provided with a stop flange '43 and a grip'portion 44. It is intended that the member 4| be oriented in either one of two particular'ways with respect to the mounting structure. -For that reason, the tube 22 is provided at diametrically opposite points with slightly elongated slots 46 and 41 into which a spring pressed detent 48 can project.

As especially shown in Figures 4 and 5, the detent 48 is disposed at the end of-a "pin 49 having a shoulder thereon slidable in a cross bore 52. The rod-49 adjacent its innermost end i r id i h. an en a g d. u 54 encompassing 'part 'of an: extensionspring 56 seated'in the bottom-of the bore '52. Designed to cooperate with the cup 54 is a cam surface51'on a plunger 58 coaxially disposed to slide in an 'end bore 59 withinfthe plug "4 lfand also having an elongated slot 6| cut therein so that the member 581 can straddle the rod '49'f'with thejcarnportion or surfacet'f in engagement with the cup "54;"

In-the ordinary'action of'thisdevice, the spring 56 projects the detent "48 and forces the -cup 54 against the cam surface 51"to expel orproject the'plunger 5 8 until the end of the-"cam surface 51 contacts the cup to serve as a stop; However,

whenthe operator depresses the plunger 58, the

carn'surfacef 51" depresses the? cup 54 to compress the spring 56 and simultaneouslywithdrawsthe detent-button48 within the'cross bore 52 so that then the plug 4| is axially movable out of the Sleeve 22' andv isfalso freely rotatable therein.

Since the 'slot'46 and'the slot 41 are circumtent 48 fwhile restricting the axial'movement of the plug 4| does permit slight rotary oscillation of the plug in either of two positions depending upon whether the detent' button is within the upper slot 46- or the lower slot 41. To serve as an indication of the orientation of the plug 4|, the hand; grip portion 44 is provided with a'fiat 52 on one side only. With this arrangement, the plug 4| can be put. into the sleeve 22 in either 'ferentijally elongated slightly, 'the projected deof two substantially diametrically opposite posi- 4 accommodation in a rotary or circumferential direction.

When the plug is so installed, it projects through the bore and extends farther into the previously existing cross bore |3 in the door. Depending upon the back set of the particular new lock to be installed, it is desirable to provide a new cross bore having either an axis 66 or an axis 6. displaced therefrom. For that reason, the plug 4| is provided with a cross passageway 68 corresponding to the axis 66 and a cross passageway 69 corresponding to the axis 61. These cross passageways are arranged with their axes in the same hor'iz'ontalplane as the axis i2 and at right angles or perpendicular thereto.

Designed to operate in either of the passageways 6501' 69' isa pilot rod extending from a cuttingtool designed to be rotated by means of a chuck 13 of any standard kind. Included in the @00 H an nnular servitude. ingt h B n th eadiii ed hei piaad pppsqt t he rod 1. b a r insp teand u When e hu k .31 fiv lved' n t a p o i t direction andis simultaneously advanced with the pilot rod it within the guide passage 69, for example, the saw teeth 16 cut a kerf in the material ofthe door panel 6 beginning with the side face 8. The kerf is Crescent shaped or arcuate and intersects the previously cut, bore. However, the saw is not defiected from its propel. location because as it advances it is continually guided by the rod 7|. in the plug 4|.

Ifhe saw 141s continually rotated. and advanced until such'time as it is at or slightly past the central, plane ofrthe door. To accommodate such motion, as indicated. by the arrows 18 in Figure l, the plug 4|. is provided with a cut out or relievecl slot 15 affording adequate clearance for the rotating saw blade. ""But so that the'saw cannot be advanced too far and dull its teeth by contact with the metal plug 4 the guide rod 1| at an appropriate axial location is enlarged to form a shoulder 8| engageable with a comparable shoulder BZformed by a counterbore 83v in the plug. Thus. when the saw l4has been turned and advancedto an appropriate extent, the shoulder 8| abuts the shoulder 82, and no further advancement can be made. At, that time the saw is backed off and the rod H is removed from engagement with the guide 4| leaving a partially severed crescent shaped block of door material.

The user then depresses the thumb button 58 and rotates the guide 4| a half turn as indicated by the flat 62. The button 58 is then released and. snaps into position. Just as in the first utilization of the structure, the guide rod then projects into the cross bore l3 but with the passage ways 68 and 69facing in the opposite direction. The saw 14 is then moved to the opposite side of the door adjacent the face I as shown in Figure 6, the pilot rod 1| is put through the guide passage 69, and the saw is again rotated and advanced against the door face. If it should happen that the door face is not exactly planar or is'not exactly at right angles to the position of the guide plug 4|, the initial contact of the saw teeth with the material of the door is. sufficient to cause a slightrotation of the guide plug, 4|, permitted by the circumferential clearance in the slots 46, and 47, so that the cut begins at an appropriate axial attitude.

The chuck 13 is rotated and the saw then cuts in the directionofthe arrows 84 into the door panel from the face 1 until such time as the saw cut merges with the previously made out or until such time as shoulders 8| and 82 again come into abutment. When that occurs, the saw is withdrawn, the completelyv severed crescent shaped block of material is likewise withdrawn, and the new hole is completed.

Afterthe saw has been withdrawn, the guide plug 4| is extracted from the remaining .Glamp structure '16 and'i'i orthe entire mechanism is removed from the door.

Upon the installation of the new look, the various parts thereof are appropriately accommodated in the correct location. It is quite customary to provide roses or escutcheons of sufficient area or extent to overlie or cover the essentric portion of the cross hole l3 not needed for the new lock location.

In some instances it is preferred to provide a slightly variant form of guide sleeve and guide plug. As especially shown in Figures '7 to inclusive, in this case the guide sleeve 9! is provided on opposite diameters with a pair of circumferential slots 92 and 93 each of which is connected by a longitudinal cut 94 with the edge of the sleeve 9 I. Adapted to be snugly received in the sleeve is a guide plug 96 having a thumb turn 91 at one end thereof formed with a cutaway portion 98 to serve as an indicator of orientation. Located in the guide plug 96 in a cross bore I0! is a coil spring I02 seated in the bore and pressing against an enlarged plunger I03 slidable in the bore yet prevented from escaping by staked portions 194. A reduced pin I06 extends from the plunger I03 and terminates in an enlarged head I01.

In the use of this particular structure, for initial engagement the user depresses the pin I06 by pressure against the head It? and compresses the spring I92 until the pin I06 passes axially or lengthwise through the selected connecting slot 94, and into the circumferential slot 92. The pin then being released, the spring I32 projects the pin until the intermediate body H38 thereof fits snugly in an axial direction within the slot 92. Since the slot 92 is elongated, there is some circumferential adjustment permitted but the axial location is fixed. When the guide plug is to be located substantially 180 degrees away, in its other position, the user depresses the pin I06, withdraws the plug slightly until the pin is outside of the sleeve 9|, rotates the plug to register with the slot 94 and then repeats the previous operation until the pin I96 has passed through the other slot 93 and has sprung into final location, as shown in Figure 10.

What is claimed is:

1. A reboring jig for use on a door panel comprising a clamp engageable with said door panel, a guide sleeve on said clamp, a plug bearing within said sleeve and extending into a cross hole in said door panel, said plug having a cross passageway therein, a rotatable rod bearing in said passageway, and a cutting tool on said rod.

2. A reboring jig for use on a door panel comprising means for engaging said door panel, a guide sleeve on said clamp, a plug bearing within said sleeve and extending into a cross hole in said door panel, said plug having a cross passageway therein, a rod rotatably bearing in said passageway, and a circular saw blade mounted on said rod for engagement with said door panel.

3. A reboring jig for use on a door panel comprising means extending into a cross hole in said door panel and defining a cross passageway therein, a rod rotatably bearing in said passageway, and a circular saw blade mounted on said rod for engagement with said door panel.

4. A reboring jig for use on a door panel comprising a plug extending into a cross hole in said door panel and defining a cross passageway therein, means for clamping said plug to said door panel, a rod rotatably bearing in saidpassageway, and a rotatable cutting tool on said rod for engagement with said door panel.

5. A reboring jig for use on a door panel comprising a guide sleeve, means for fastening said guide sleeve with respect to said door panel, a plug bearing within said sleeve in either of two selected positions, a rotatable cutting tool, and a rod on said tool engageable with said plug in either of said ositions.

6. A reboring jig for use on a door panel comprising a guide sleeve, means for fastening said guide sleeve to said door panel, a plug rotatable within said sleeve between two selected positions, a cutting tool, and means on said tool for supporting said tool on said plug in either of said selected positions.

7. A reboring jig for use on a door panel comprising a guide, means for positioning said guide on said door panel, a plug receivable in said guide and adapted to extend into a cross hole in said door panel, a cutting tool, and means on said tool for supporting said tool on said plug.

8. A reboring jig for use with a door panel having an edge hole intersecting a cross hole comprising a plug adapted to extend through said edge hole into said cross hole, means forming a cross passageway on said plug, a cutting tool, and means on said cutting tool rotatable and slidable within said cross passageway.

9. A reboring jig for use with a door panel comprising a lever, a guide sleeve on said lever, means engaging the sides of said door panel for clamping said lever over the edge of said door panel, a plug having a passageway therein and rotatable in said guide sleeve, means for holding said plug against rotation in said guide sleeve, a circular saw, and a rod disposed axially of said saw and adapted to be disposed in said passageway.

10. A reboring jig comprising a circular cylindrical plug having a cross passageway through one end thereof, a rod rotatable and slidable in said passageway, and a cutting tool on said rod extending toward said plug, there being a cut away portion of said plug to afford clearance for said tool.

11. A reboring jig comprising a circular cylindrical plug having a cross passageway through one end thereof, a rod rotatable and slidable in said passageway, a cutting tool on said rod extending toward said plug, there being a cut away portion of said plug to afiord clearance for said tool, and a shoulder on said rod engageable with said plug to stop movement of said tool toward said plug.

12. A reboring jig for use with a door panel having an edge hole and an intersecting through hole comprising a clamp, means for gripping said clamp to the sides of said door panelfa guide sleeve on said clamp disposed substantially coaxially with said edge hole, a plug disposable in said guide sleeve and adapted to extend through said edge hole into said through hole, means for holding said plug against axial movement in said guide sleeve and for holding said plug against substantial rotation within said guide sleeve, said plug having a cross passageway through one end thereof, a rod adapted to extend into said through hole and slidably and rotatably disposed in said cross passageway, a cutting tool on said rod ex- 7 tending tpwarq said plug, there being a cut away REFERENCES CITED P91713911 i Said l to afford clearance said The following references are of record in the $901, and a, shqulder on said rod engageable with me of this patent: said plug to stop movement of said tool toward said plug. 5 UNITED STATES PATENTS Number Name Date RN S L- S 1,919,900 Moller July 25, 1933 2,140,192 Thatcher Dec.. 13, 1938 

